Segmented Side Sill Assembly for EV Battery Side-Impact Rigidity
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Solution Overview
Problem
The existing side sills in vehicles, particularly in eco-friendly vehicles, are prone to deformation during side collisions, which can lead to damage and potential fire from high voltage batteries due to insufficient strength, and are difficult to handle during manufacturing due to their one-piece construction from the front pillar to the rear wheelhouse.
Innovation Solution
A side sill assembly for eco-friendly vehicles is designed with a center member fastened to the center floor panel, featuring a cylindrical cross-section with partition walls to absorb collision energy, and separate front and rear outer members that are manufactured by extrusion and assembled separately, enhancing rigidity and facilitating handling during vehicle assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the side sill is formed as one piece from the front pillar to the rear wheelhouse, then the structural strength is improved, but the ease of manufacture deteriorates due to difficulty in handling during assembly
Solution Approach 1:
The side sill is divided into multiple segments: a first side sill member, a second side sill member, and a third side sill member. These segmented members are connected through connection portions with fastening members, allowing easier handling and assembly while maintaining the required structural strength through the integrated connection system
2Reliability
If the side sill strength is increased to prevent deformation during side collision, then the reliability is improved, but the device complexity increases due to the need for additional reinforcement structures
Solution Approach 1:
The side sill is segmented into multiple members with connection portions that include reinforcement structures. This segmentation allows strategic placement of reinforcement elements at critical connection points rather than throughout the entire structure, maintaining reliability while reducing overall complexity
Solution Approach 2:
The connection portions utilize composite construction combining the side sill members with reinforcement structures and fastening members. This composite approach provides enhanced strength and deformation resistance at critical locations without requiring the entire side sill to be overly complex
3Stability of the object's composition
If the side sill is designed as a one-piece structure, then the structural integrity is improved, but the ease of operation deteriorates during vehicle assembly
Solution Approach 1:
The side sill system is divided into separable members (first, second, and third side sill members) that can be independently handled and positioned during assembly. The connection portions with fastening members enable straightforward joining operations, improving ease of operation while maintaining structural integrity through the connected assembly
4Reliability
If partition walls are added to the cylindrical cross-section to absorb collision energy, then the reliability is improved, but the device complexity increases due to additional internal structures
Solution Approach 1:
Partition walls are added to the cylindrical cross-section of the side sill members to divide the internal space into multiple compartments. This segmentation creates collision energy absorption zones that enhance reliability during side collisions, while the modular nature of the partition design allows for efficient manufacturing and assembly
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The side sill assembly reduces deformation and damage to high voltage batteries during side collisions by improving rigidity and securing the battery's position, while also simplifying the assembly process by allowing separate handling and use of conventional facilities.
Implementation Method 1
each of the center member, the front outer member, and the rear outer member has a cylindrical cross section at least one partition wall for partitioning the inside thereof horizontally and vertically to absorb collision energy upon side collision
Implementation Method 2
The center member, the front outer member, and the rear outer member are manufactured by extrusion
Data Source
AI summary
A side sill assembly for an eco-friendly vehicle includes: a center member fastened to a side surface of a center floor panel of the eco-friendly vehicle; a front outer member fastened to a front end of the center member; and a front inner member located inside the front outer member and fastened to a front apron and a dash panel. In particular, a battery frame fastened to a side surface of a high voltage battery is fastened to at least one of the front inner member and the center member in a longitudinal direction of the vehicle.